Description
nora® Lunatec Fusion 40 is a medium density expanded EVA sheet designed for orthotic and prosthetic fabrication using adhesive free fusion bonding technology. With a hardness of approximately 40 Shore A and a density of around 0.20 g/cm³, this material provides an excellent balance between cushioning, stability, and elastic recovery. It is well suited for multilayer orthotic constructions, insoles, and structural comfort components where reliable bonding and dimensional stability are required.
As part of the Lunatec Fusion system, the material allows permanent bonding between layers without the need for adhesive. When heated and pressed together, the EVA surfaces fuse during the cooling phase, creating a strong and durable bond without glue, solvents, or intermediate layers. This enables faster production, cleaner processing, and environmentally friendly workshop conditions.
Material specification
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Hardness: approx. 40 Shore A
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Density: approx. 0.20 g/cm³
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Surface: smooth or perforated
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Sheet format: approx. 1040 × 625 mm (40.9 inch × 24.6 inch)
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Edges: trimmed for clean processing
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Thermoforming temperature: approx. 130°C (266°F)
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Bonding: fusion bonding without adhesive within the Lunatec Fusion range
Available versions
Smooth
Perforated
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Colour: 09 white
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Thickness: 4 mm, 8 mm
Intended applications
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Orthotic insoles and footbeds
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Multi layer EVA constructions
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Cushioning and stabilising layers
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Comfort layers in orthoses
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Lightweight midsole builds
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Sandwich constructions without adhesive
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CAD CAM and manual fabrication workflows
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Diabetic and sensitive foot applications
Key properties
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Lightweight and elastic EVA
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Good dimensional stability
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Reliable elastic recovery
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Comfortable walking properties
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Fusion bonding without glue
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Clean and fast workshop processing
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No discoloration caused by adhesive
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Strong bond after cooling
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Suitable for deep drawing and vacuum forming
Fusion bonding principle
Lunatec Fusion materials bond directly to each other when heated and pressed together. During the cooling phase, the warmed EVA layers fuse permanently without adhesive or intermediate layers. Testing of peel resistance according to DIN EN 1392 has shown that the bond created can be stronger than the material itself. In many cases, the material will tear before the bonded layers separate.
Lunatec Fusion materials were developed to allow healthy and environmentally friendly fabrication without the use of adhesive. However, the material can also be processed with conventional EVA adhesives if required.
Processing instructions
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Roughen all bonding surfaces before heating
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Use perforated material where possible for optimal bonding
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Oven setting: approx. 130°C / 266°F
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Follow recommended heating times
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Apply sufficient pressure during vacuum forming
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Rule of thumb: heating time multiplied by two equals ideal cooling time
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Perforated sheets heat faster and may reduce heating time
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Cooling time depends on total material thickness
Advantages of fusion processing
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No adhesive required
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Reduced fabrication time
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Clean working environment
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No solvent fumes
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No glue contamination
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No drying time
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Immediate use after cooling
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Strong permanent bond
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Environmentally friendly production
nora® Lunatec Fusion 40 is ideal for orthotic, prosthetic, and orthopaedic footwear workshops that require a reliable EVA material with moderate firmness, strong bonding capability, and efficient adhesive free processing within the Lunatec Fusion system.
